System and process for replacing a core of diesel emission control device

ABSTRACT

A system for removing an existing core from a diesel emission control device (DECD) housing and a system for installing a replacement core into the DECD housing. The system for removing the existing core comprising a core press station, a control station, and a decore shaft. The system for installing the replacement core comprising a core press station, a control station, and a recore shaft. A stuffing funnel and spacer may be used to install the replacement core. In certain embodiments, processes for removing the existing core and installing the replacement core may comprise the steps of pressing the existing core out of the DECD housing, collecting the existing core into a collection container, sealing the collection container, wrapping the replacement core with matting, lubricating the matting, and pressing together the replacement core and the existing DECD housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional PatentApplication Ser. No. 63/220,887, filed Jul. 12, 2021, entitled “Systemand Process for Replacing a Core of Diesel Emission Control Device,”which is herein incorporated by reference in its entirety.

TECHNICAL FIELD

The invention relates in general to the recycling of diesel emissioncontrol devices (DECDs), and in particular to a system and process forremoving and inserting cores of diesel emission control devices, such asdiesel particulate filters (DPFs), diesel oxidation catalysts (DOCs),and/or selective reduction catalysts (SCRs).

SUMMARY

In an embodiment, a system is disclosed comprising of a press forremoving and inserting cores of various shapes and sizes and anadjustable wrapping station for preparing a replacement core plusvarious tools and equipment for implementing a process of removing andinserting cores using the disclosed system.

In another embodiment, a system for removing an existing core from aDECD housing may comprise: a core press station having a piston and aworking platform; a control station for controlling movement the piston;and a decore shaft connected to the piston, whereby movement of thepiston is configured to push the existing core out of the DECD housing.The control station may include a two-handed sensor system foractivation control of the core press station.

In another embodiment, the system for removing an existing core from aDECD housing may further comprise: a push plate positioned upon theworking platform, the push plate having a first internal apertureconfigured to pass the existing core therethrough; a pushout donutdemountably connected to the push plate, the pushout donut having asecond internal aperture configured to pass the existing coretherethrough; and a collection container connected between the pushplate and the pushout donut, the collection container configured toreceive the existing core.

In another embodiment, the decore shaft includes a decore shaft portionhaving a first female aperture configured to connect to the piston, anda decore engagement plate disposed opposite the first female aperture.

In yet another embodiment, the first internal aperture comprises a firstdiameter, the first diameter is greater than an inside diameter of theDECD housing. In another embodiment, the second internal aperturecomprises a second diameter, the second diameter is approximately equalto an inside diameter of the DECD housing.

In another embodiment, a system for installing a replacement core into aDECD housing comprising: a core press station having a piston andworking platform; a control station for controlling movement of thepiston; a recore shaft connected to the piston; a stuffing funnelconfigured to couple to the DECD housing proximate an upper end of theDECD housing; and a spacer connected to the working platform, the spacerconfigured to fit within the DECD housing proximate a lower end of theDECD housing, whereby movement of the piston is configured to press thereplacement core through the stuffing funnel and into the DECD housinguntil the replacement core abuts the spacer. The control station mayinclude a two-handed sensor system for activation control of the corepress station.

In another embodiment, the system for installing a replacement core intothe DECD housing includes an adjustable wrapping station having a set ofrollers for supporting the replacement core. In an embodiment, a mattingmay be connected to the replacement core.

In yet another embodiment, the recore shaft includes a recore shaftportion having a second female aperture configured to connect to thepiston, and a recore engagement plate disposed opposite the secondfemale aperture.

In another embodiment, a process for removing an existing core from aDECD housing may comprise the steps of: (1) providing a core pressstation having a working platform; (2) connecting a collection containerbetween the working platform and the DECD housing; (3) aligning the DECDhousing over the collection container; (4) pressing the existing coreout of the DECD housing; and (5) collecting the existing core into thecollection container.

In another embodiment, the process for removing an existing core from aDECD housing may include the step of sealing the collection containerand sending the collection container offsite.

In another embodiment, a process for inserting a replacement core into aDECD housing, comprising the steps of: (1) providing a core pressstation having a working platform; (2) placing the DECD housing onto theworking platform; (3) coupling a stuffing funnel to the DECD housing;(4) wrapping the replacement core with a matting; (5) wrapping thematting with a wrapping material; (6) lubricating the stuffing funnel,an interior surface of the DECD housing, and the wrapping material; and(7) pressing the replacement core through the stuffing funnel and intothe DECD housing.

In another embodiment, the process for inserting a replacement core intoa DECD housing may include the additional steps of: determining anoverhang distance between an unobstructed side of the DECD housing and aface of an existing core; selecting a spacer based the overhangdistance; placing the spacer onto the working platform; aligning theDECD housing over the spacer; and stopping the pressing step when thereplacement core abuts the spacer.

In another embodiment, the process for inserting a replacement core intoa DECD housing may include the additional steps of: determining ahousing flow direction of the DECD housing; aligning the DECD housingwith the working platform based on the housing flow direction so thatthe housing flow direction is directed towards the working platform;determining a core flow direction of the replacement core; and aligningthe core flow direction with the housing flow direction.

In yet another embodiment, the process for inserting a replacement coreinto a DECD housing may include the step of selecting the stuffingfunnel based on an inside diameter of the DECD housing and an outsidediameter of the replacement core.

In yet another embodiment, the wrapping material may comprise a wrappingtape.

There is also an embodiment of a process for removing and insertingcores into DECDs. In certain embodiments, the process comprises pressingthe existing core out of a DECD housing and into a collection container,sealing the collection container, wrapping a replacement core withmatting, and inserting the replacement core into the existing DECDhousing.

The systems and processes for removing and inserting a replacement coreprovides for an efficient and economical means to refurbish a dieselemission control device.

These and other features, and advantages, will be more clearlyunderstood from the following detailed description taken in conjunctionwith the accompanying drawings. It is important to note the drawings arenot intended to represent the only aspect of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings constitute a part of this specification and includeexemplary embodiments of the disclosed subject matter and illustratevarious objects and features thereof.

FIG. 1 is a front perspective view of a system for removing andinserting a core into a diesel emission control device.

FIG. 2A is a front view of an embodiment of a core press station and acontrol station.

FIG. 2B is a side view of an embodiment of a core press station and acontrol station.

FIG. 2C is an isometric view of an embodiment of a core press stationand a control station

FIG. 3A is an isometric view of an embodiment of a decore shaft.

FIG. 3B is an isometric view of an embodiment of a push plate andpushout donuts.

FIG. 4A is an isometric view of an embodiment of a recore shaft.

FIG. 4B is an isometric view of an embodiment of a stuffing funnel.

FIG. 4C is an isometric view of an embodiment of a plurality of spacers.

FIG. 4D is a side view of an embodiment of a caliper.

FIG. 5A is a flow chart illustrating an embodiment of a method forremoving an existing core from a DECD unit.

FIG. 5B is a flow chart illustrating an embodiment of a method forpreparing a press operation.

FIG. 6A is a perspective view of an embodiment of a DECD unit.

FIG. 6B is a perspective view of an embodiment of a DECD housing.

FIG. 6C is a perspective view of an embodiment of a replacement core.

FIG. 6D is a perspective view of an embodiment of a DECD housing.

FIG. 6E is a perspective view of an embodiment of a first end of a DECDunit.

FIG. 6F is a perspective view of an embodiment of a second end of a DECDunit.

FIG. 6G is a perspective view of an embodiment of a DECD unit.

FIG. 6H is a side view of an embodiment of a decore shaft connected to apiston.

FIG. 6I is a perspective view of an embodiment of a pushout donut.

FIG. 6J illustrates the DECD unit position on top of the pushout donut.

FIG. 6K illustrates the alignment of a DECD housing with a pushoutdonut.

FIG. 6L is a top view illustrating operation of a two-handed sensorsystem.

FIG. 6M is a perspective view of the core press station prior to a coreremoval process.

FIG. 6N is a perspective view of the core press station during a coreremoval process.

FIG. 6O is a perspective view of the existing core being deposited intoa collection container during a core removal process.

FIG. 6P is a perspective view of the existing core deposited into acollection container after a core removal process.

FIG. 6Q is a cross-section view of an embodiment of the DECD housing,push plate, pushout donut, and collection container configured for acore removal process.

FIG. 7A is a flow chart illustrating an embodiment of core insertionprocess.

FIG. 7B is a flow chart illustrating an embodiment of a core preparationsub-process.

FIG. 8A is a perspective view of an embodiment of spacers and a supportplate.

FIG. 8B is a perspective view of an embodiment of the recore shaft, DECDhousing, and spacers.

FIG. 8C is a perspective view of an embodiment the DECD housing andstuffing funnel position upon the working platform of the core pressstation.

FIG. 8D is a perspective view of an embodiment of an adjustable wrappingstation.

FIG. 8E is a perspective view of an embodiment of an adjustable wrappingstation supporting a replacement core and matting.

FIG. 8F is a perspective view of an embodiment of a replacement coreprepared with a matting and a wrapping material.

FIG. 8G is a perspective view of an embodiment of a replacement coreprepared with a matting and a wrapping material.

FIG. 8H is a perspective view of an embodiment of a replacement coreprepared with a matting and a wrapping material.

FIG. 8I is an illustration of the preparation of the stuffing funnelwith a lubricant.

FIG. 8J is an illustration of the preparation of the wrapping materialwith a lubricant.

FIG. 8K a top view illustrating operation of a two-handed sensor systemduring a core insertion process.

FIG. 8L is a perspective view of an embodiment of core insertionprocess.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of thepresent inventions, reference will now be made to the embodiments, orexamples, illustrated in the drawings and specific language will be usedto describe the same. It will nevertheless be understood that nolimitation of the scope of the invention is thereby intended. Anyalterations and further modifications in the described embodiments, andany further applications of the principles of the inventions asdescribed herein are contemplated as would normally occur to one skilledin the art to which the invention relates.

Well-known elements are presented without detailed description in ordernot to obscure the present invention in unnecessary detail. For the mostpart, details unnecessary to obtain a complete understanding of thepresent invention have been omitted inasmuch as such details are withinthe skills of persons of ordinary skill in the relevant art. Detailsregarding control circuitry or mechanisms used to control the rotationof the various elements described herein are omitted, as such controlcircuits are within the skills of persons of ordinary skill in therelevant art.

The detailed description includes the disclosure of numerical ranges.Numerical ranges should be construed to provide literal support forclaim limitations reciting only the upper vale of a numerical range, andprovide literal support for claim limitations reciting only the lowervalue of a numerical range.

When directions, such as upper, lower, top, bottom, clockwise,counter-clockwise, are discussed in this disclosure, such directions aremeant to only supply reference directions for the illustrated figuresand for orientation of components in respect to each other or toillustrate the figures. The directions should not be read to implyactual directions used in any resulting invention or actual use. Underno circumstances, should such directions be read to limit or impart anymeaning into the claims.

The disclosed subject matter will now be described with reference to thedrawing figures, in which like reference numerals refer to like partsthroughout. For purposes of clarity in illustrating the characteristicsof the present disclosed subject matter, proportional relationships ofthe elements have not been maintained in the drawing figures. In somecases, the sizes of certain small components have been exaggerated forillustration.

Turning now to FIG. 1 , there is presented one embodiment of a system100 for removing an existing core and inserting a replacement core intoa diesel emission control device (DECD). Both the existing core and thereplacement core are typically cylindrical in shape and comprise a crosssection having a circular shape. The system 100 may be configured toremove and replace cores having cross sections of various shapes, suchas a square, rectangle, triangle, parallelogram, rhombus, trapezium,octagon, hexagon, pentagon, ellipse, oval, and other shapes known in theart. In the illustrated embodiment, the system 100 comprises a corepress station 102 and a control station 104. In another embodiments, thesystem further comprises an adjustable wrapping station 106. In someembodiments, however, the control station 104 may be integrated into thecore press station 102.

In certain embodiments, the adjustable wrapping station 106 may be astandalone unit as illustrated in FIG. 1 or integrated into thestructure of the core press station 102. In yet other embodiments, theadjustable wrapping station 106 may be eliminated. In certainembodiments, the adjustable wrapping station 106 provides a primaryroller to dispense a wrapping material in addition to a plurality ofhorizontally aligned secondary rollers to allow for a convenient turningof a replacement core and wrapping of a wrapping material, such aswrapping tape, around a replacement core and matting material as will bedescribed in more detail below.

FIG. 2A is a front view of the core press station 102 and the controlstation 104. FIG. 2B is a side view of the core press station 102 andthe control station 104 and FIG. 2C is an isometric view of the corepress station 102 and the control station 104.

In certain embodiments, the core press station 102 includes a press suchas a hydraulic press, which may include a press frame 110. In certainembodiments, the press frame 110 includes vertical columns 112, one ormore top cross beams 114, one or more lower cross beams which form partof a working platform 116, and foundation brackets 118 which are coupledto the lower ends of the vertical columns 112. In certain embodiments,the working platform 116 is adjustable via bolt holes 120 and supportbolts or pins (not shown). FIG. 2A-2C illustrate the working platform116 in an extreme upper position A and also in an extreme lower positionB.

In certain embodiments, a master cylinder 122 is coupled to the one ormore top cross beams 114. The master cylinder 122 provides the forcenecessary to press the existing and replacement cores out of and intothe housing as described below.

In certain embodiments, the control station 104 comprises a master pumpmotor 124 which, in the illustrated embodiment, runs a hydraulic pump tocreate oil flow and pressure used during operation. In certainembodiments, a hydraulic oil tank 126 is positioned below the masterpump motor 124. In the illustrated embodiment, a control box 128 issupported by a control station frame 130. In certain embodiments, thecontrol box 128 contains electrical circuits for supplying power to themaster pump motor 124 and a PLC programmable controller (not shown) forcontrolling the operation of the master pump motor 124 and the mastercylinder 122. The various circuitry and controllers in the control box128, the master pump motor 124, and the master cylinder 122 areintegrated together with the hydraulic lines, electrical wiring, anddevices known in the art.

FIG. 3A-3B illustrate various components for use with the core pressstation 102 during a core removal process. FIG. 3A is an isometricdrawing illustrating a decore shaft 150 which is designed to removecores from the DECD housings as explained below. In certain embodiments,the decore shaft 150 contains a decore shaft portion 152 where one endis coupled to a decore engagement plate 154. In an embodiment, thedecore engagement plate 154 comprises a circular disk. In certainembodiments, a first female aperture 156 having internal threads isdefined within the longitudinal center of the decore shaft portion 152.The first female aperture 156 is sized to removably engage exteriorthreads defined on a piston (not shown) of the master cylinder 122. Thedecore engagement plate 154 disposed opposite the first female aperture156.

FIG. 3B is an isometric drawing illustrating a push plate 180 and aplurality of pushout donuts 182 in various sizes for coupling to acollection container, such as a plastic collection bag (not shown).

FIGS. 4A-4D illustrate various components for use with the core pressstation 102 during a core insertion process. FIG. 4A is an isometricdrawing illustrating a recore shaft 200 which is designed to insertcores into the DECD housings as explained below. In certain embodiments,the recore shaft 200 comprises a recore shaft portion 202 where one endis coupled to a recore engagement plate 204. In an embodiment, therecore engagement plate 204 comprises a disk. In certain embodiments, asecond female aperture 206 having internal threads is defined within thelongitudinal center of the recore shaft portion 202. The second femaleaperture 206 is sized to removably engage exterior threads defined on apiston (not shown) of the master cylinder 122. The recore engagementplate 204 disposed opposite the second female aperture 206.

FIG. 4B is an isometric drawing of a stuffing funnel 210 sized to fitover one end of a DECD housing to aid the insertion process as explainedbelow.

FIG. 4C is an isometric drawing of spacers 220 which are involved in theprocess of inserting a core into a DECD housing as explained below. FIG.4D illustrates a caliper 222, such as an 18 inch caliber known in theart. In certain embodiments, the various components described in FIGS.3A, 3B, 4A-4E may be made of steel or another material designed withsufficient strength and hardness to withstand the forces of a press.

Core Removal Process

Referring now to FIGS. 5A-6Q, the manner of using one embodiment of thesystem 100 will be illustrated via a core removal process 500 forremoving an existing core from a DECD unit 600. The steps of the coreremoval process 500 are illustrated in FIG. 5A which is a process flowchart. Various details relating to the individual steps in the coreremoval process 500 are presented in FIGS. 6A-6O.

The core removal process 500 starts at step 501 and flows to step 502where an operator may inspect the DECD housing 610 to check for cracks,failed welds, broken brackets, and retaining rings. During thisinspection step, the operator can determine which side the core will beremoved. In a preferred embodiment, the least unobstructed side is thepreferred side where the core will be pushed out of the DECD housing610.

In step 504, data regarding the DECD unit 600 may be collected andrecorded. For instance, an operator may measure and record an overhangdistance D between an unobstructed side 602 of the DECD housing to aface 604 of the existing core 606 as illustrated in FIG. 6A. Theoverhang distance D will be the “depth to push to” in the followingsteps. The operator may also determine a housing flow direction of theDECD unit 600. The housing flow direction is usually marked by an arrow608 on the exterior of the DECD housing 610 as illustrated in FIG. 6B.If the DECD housing 610 does not have any markings indicating thehousing flow direction, the side of the existing core 606 with the mostsoot buildup will likely be the inlet side. Additionally, the operatormay measure and record an outer dimension (O.D.) of a replacement core804 using a caliper 222, or other suitable equipment, which is measured1800 from outside of to outside of the core as illustrated in FIG. 6C.The operator may also measure and record the interior dimension (I.D.)of the DECD housing 610 using a caliper 222, or other suitableequipment, which is measured 180′ apart from inside to inside of theDECD housing 610 as illustrated in FIG. 6D.

In certain situations, the DECD unit 600 may be used to determine theexit end for the existing core 606. FIG. 6E illustrates a first end 612of a DECD unit 600 and FIG. 6F illustrates a second end 614 disposedopposite the first end 612. As illustrated, the first end 612 in FIG. 6Eis obstructed by a flange 616 and handles 618. In contrast, the secondend 614 illustrated in FIG. 6F appears to be clear of obstructions. Inthis specific example, the exit end for the existing core 606 andassociated DECD housing 610 will be the second end 614.

FIG. 6G illustrates an exemplary situation where there is an obstructionsuch as rings 620 on both ends of the DECD unit 600. In this situation,the operator may need to remove the obstruction from one end to createan exit end. The “push,” therefore, will come from the opposing orobstructed end. The operator may need to check for, and remove, otherobstructions from the DECD housing before the process continues such as,bungs, flow sleeves, cones, flanges, or retaining rings.

In step 506, the core press station 102 may be set up for the decoringor core removal process. Turning now to FIG. 5B, there is illustrated apress preparation sub-process 550 for setting up the core press station102 in order to remove a core from a DECD unit. This press preparationsub-process 550 begins at step 551 where the flow goes to step 552,which in some embodiments involves the inspection of the core pressstation to ensure that power is connected, there are no leaks in thehydraulic lines, the support pins are secured, and tooling, such as thepush plate 180, is secured and bolted in place.

In step 554, the decore shaft 150 may be coupled to a lower end of apiston of the master cylinder 122. In certain embodiments, the firstfemale aperture 156 of the decore shaft 150 is rotatably coupled to thethreaded surface 621 of the piston as illustrated in FIG. 6H.

In step 556, a collection container 622 is positioned and secured to thecore press station 102. In certain embodiments, a collection bag may beused as a collection container 622. In such embodiments, the collectionbag is placed through a center aperture of the push plate.

In step 558, the operator may then determine and select a pushout donut182 to hold the collection bag in place as illustrated in FIG. 6I. Todetermine the correct size of the pushout donut 182, the operator maymeasure the outside diameter of the core and best match the measureddiameter to a pushout donut 182. In some embodiments, there are avariety of pushout donuts 182 in various sizes that are likely to beencountered with typical DECD units.

In step 560, the pushout donut 182 is demountably connected to the pushplate 180 and the container bag to secure the container bag to the pushplate as indicated in FIG. 6I. At step 562, the press preparationsub-process 550 is compete and the flow returns to the core removalprocess 500.

Referring to FIG. 6Q, in one embodiment, the collection container 622 issecured between the pushout donut 182 and the push plate 180 so as tocreate an tight seal between the collection container and pushout donut182. The push plate 180 comprising a first internal aperture 626 havinga first diameter D₁ configured to pass the existing core therethrough.The first diameter D₁ is greater than the inside diameter (I.D.) of theDECD housing 610. The pushout donut 182 comprising a second internalaperture 628 having a second diameter D₂ configured to pass the existingcore therethrough; wherein the second diameter D₂ is approximately equalto the inside diameter (I.D.) of the DECD housing 610.

In step 510 of the core removal process 500 (FIG. 5A), the DECD unit ispositioned on top of the pushout donut 182 and aligned with the apertureof the pushout donut 182 as indicated in FIG. 6J. In other words, theinside diameter of the DECD housing is aligned with the inside diameterof the pushout donut aperture from underneath as indicated in FIG. 6K.In some embodiments, the alignment is checked in three locations atapproximately 120° around the diameter of the aperture as indicated inFIG. 6K.

In step 512, the existing core of the DECD unit may be pushed out. Incertain embodiments, the control station 104 may comprises a two-handedsensor system for activation control of the core press station. Thetwo-handed sensor system requires an operator to use both of his/herhands, one on each sensor, to activate the hydraulic pump as illustratedin FIG. 6L. The two-handed sensor system reduces the risk of operatorinjury since both of the operator's hands will be out of the way amoving piston when the core press station is in operation. Once thehydraulic pump is activated, the piston 624 of the master cylinder willbegin to move in a downward motion. As explained previously, the piston624 is coupled to the decore shaft 150 and decore engagement plate 154.Thus, as the piston moves in a downward direction so does the decoreshaft 150 and decore engagement plate 154. When the decore engagementplate 154 reaches the top of the existing core 606 of the DECD unit 600,the decore engagement plate 154 begins to push the existing core 606 outof the DECD housing 610 as shown in FIGS. 6M-6N.

As the decore engagement plate 154 continues to push the existing core606, the existing core 606 then drops into the collection container 622,such a bag, which has been positioned and configured to receive theexisting core 606 when it drops into the collection container 622, asindicated in FIG. 6O.

In step 514, once the existing core 606 has been pushed entirely out ofthe housing and into the collection container 622, the collectioncontainer 622 may be sealed as indicated in FIG. 6P. The collectioncontainer 622 may be sealed and sent offsite for recycling. The coreremoval process 500 ends at step 516.

Core Insertion Process

Referring now to FIGS. 7A-8K, the manner of using one embodiment of thesystem 100 will now be illustrated as a core insertion process 700 forinserting a replacement core 804 into a DECD housing 610. The steps ofthe core insertion process 700 are illustrated in FIG. 7A which is aprocess flow diagram. Various details relating to the individual stepsin the core insertion process 700 are presented in FIGS. 7A-8K.

The core insertion process 700 starts at step 701 and flows to step 702where an operator may inspect an interior surface of the DECD housing610 to ensure that all the matting, gaskets or any other foreign matteris removed before the installation of a replacement core 804.

In step 704, any tooling such as the pushout donut 182 is removed fromthe working platform 116 and a support plate 802 is placed on theworking platform 116. Additionally, in certain embodiments, the removalor decore shaft 150 may be replaced with the insertion or recore shaft200. In step 706, the spacers 220 are positioned on top of the supportplate 802 having a thickness equal the overhang dimension D that waspreviously recorded above. See FIG. 8A.

In step 708, the size and model of the stuffing funnel 210 may bedetermined from the outside diameter (O.D.) of the replacement core 804and the inside diameter (I.D.) of the DECD housing 610. For examples, amapping between a model of the stuffing funnel 210 and the correspondingO.D.s and I.D.s may be selected in accordance with Table 1 below. Othersizes and models (not shown in Table 1) of the stuffing funnel 210 maybe based on the dimensions of the replacement core 804, the DECD housing610, and/or the application of the DECD unit 600.

TABLE 1 DECD Housing I.D. Replacement Core O.D. Stuffing Funnel (inches)(inches) Model 12.295-12.335 12 FUN12-01 (no flange housing)12.295-12.335 12 FUN12-02 12.452-12.492 12 FUN12-00 10.952-10.992 10.5FUN10.5-00 10.702-10.742 10.25 or 10.5 FUN10.25-00 9.452-9.492 9FUN09-00

After the stuffing funnel 210 model has been selected, in step 710, thestuffing funnel 210 may be coupled to the upper end of the DECD housing610, now empty, and the DECD housing 610 may be positioned on top of thespacers 220 and the support plate 802 as illustrated in FIGS. 8B and 8C.In certain embodiments, alignment of the stuffing funnel 210 to theinterior of the DECD housing may be important to proper insertion of areplacement core 804.

The replacement core 804 may be prepared for insertion into the stuffingfunnel 210 in step 712. Turning now to FIG. 7B, there is illustrated acore preparation sub-process 750 for preparing a replacement core 804.The core preparation sub-process 750 begins at step 751 where the flowgoes to step 752. In step 752, an identification of a housing flowdirection of the housing is made as it sits in the press frame 110. Inan embodiment, the DECD housing is aligned with the working platformbased on the housing flow direction so that the housing flow directionis pointed towards the working platform. In step 754, an identificationof a core flow direction of the replacement core 804 is determined. Forinstance, certain cores are marked with the letters “OT” on the outletof the core. This information will determine the insertion end of thecore because the housing flow direction of the DECD housing 610 shouldbe aligned and in the same direction with the core flow direction of thereplacement core 804. In some embodiments, a properly inserted core willhave the flow arrow of the DECD housing pointed to the outlet side ofthe core and the outlet side of the core will be labeled with theletters “OT”.

In step 756, a matting 806 is wrapped around the replacement core 804.In certain embodiments, the matting 806 is made from a fibrous materialknown in the art. Approximately three feet of a wrapping material 808,such as wrapping tape, may be pulled from a tape roller 810 of theadjustable wrapping station 106 as illustrated in FIG. 8D. The wrappingmaterial 808 may comprise various widths depending on the application.The matting 806 may then be placed on a set of rollers 812 of theadjustable wrapping station 106 and the replacement core 804 placed ontop of the matting 806 as illustrated in FIG. 8E. The wrapping material808 may then be tightly wrapped around the matting 806 as illustrated inFIGS. 8F and 8G. In an embodiments, the wrapping material 808 may bestandard wrapping tape.

In certain embodiments, the matting 806 may be aligned with the edgethat will first pass through the stuffing funnel 210. In step 758, thewrapping material 808 is then used to tightly wrap around the entireexterior surface of the matting 806 so that a lubricant (not shown) canbe applied to the outside of the wrapping material 808 before insertioninto the stuffing funnel 210 as illustrated in FIG. 8H. Step 760 endsthe core preparation sub-process 750 and the core insertion process 700resumes with step 714 of FIG. 7A.

In step 714, the inside of the DECD housing 610 is inspected to ensurethere is no debris inside the DECD housing 610. If the inside of theDECD housing 610 is clean, a lubricant 814 may be applied to an interiorsurface the DECD housing 610 as illustrated in FIG. 8I. In certainembodiments, the lubricant 814 may comprise canola oil, palm oil andcoconut oil and lecithin. The correct end of the matting 806 is thenplaced into the stuffing funnel 210 and the outside of the wrappingmaterial 808 is also sprayed with the lubricant as illustrated in FIG. 8. The prepared core should be carefully placed into the stuffing funnelsuch that the stuffing funnel does not move. If the stuffing funnelmoves, a misalignment may result in damage to the equipment, the DECDhousing 610 or replacement core 804.

In step 716, the replacement core replacement may be pressed into theDECD housing 610. As described above, in certain embodiments, theactivation control for the core press station 102 may comprise atwo-handed sensor system as illustrated in FIG. 8K. In other words, incertain embodiments, activation requires two hands, one hand on eachsensor to activate the hydraulic pump. Once the hydraulic pump isactivated, the piston 624 of the master cylinder 122 will begin to movein a downward motion. As explained previously, the piston 624 is coupledto the recore shaft 200 and recore engagement plate 204. Thus, as thepiston 624 moves in a downward direction so does the recore shaft 200and recore engagement plate 204. When the recore engagement plate 204reaches the top of the replacement core 804, the recore engagement plate204 begins to press the replacement core 804 into the DECD housing 610as illustrated in FIG. 8L. In another embodiment, the replacement core804 is positioned between the working platform 116 and the DECD housing610, whereby movement of the piston 624 presses the recore engagementplate 204 upon the replacement core 804 and therefore presses the DECDhousing onto the replacement core 804.

As the replacement core 804 moves through the stuffing funnel 210, theoperator may observe the core insertion process 700 to ensure that thereplacement core 804 is pushing level. If the replacement core 804begins to go out of level, the operator may stop the movement of thepiston 624 and adjust the alignment of the replacement core 804 until itis level and axially aligned with the DECD housing 610. The operatorshould also ensure that the matting 806 does not slide relative to thereplacement core 804 during the core insertion process 700. The operatormay continue to lower the piston 624 until the replacement core 804abuts one of the spacers 220. The core insertion process 700 ends atstep 718.

From the foregoing, those skilled in the art will recognize that thedisclosed subject matter provide significant advantages to the field ofremoval and replacement of DECD cores; in particular providing a system,components, methods of installation thereof. It is to be understood thatwhile certain aspects of the disclosed subject matter have been shownand described, the disclosed subject matter is not limited thereto andencompasses various other embodiments and aspects.

The abstract of the disclosure is provided for the sole reason ofcomplying with the rules requiring an abstract, which will allow asearcher to quickly ascertain the subject matter of the technicaldisclosure of any patent issued from this disclosure. It submitted withthe understanding that it will not be used to interpret or limit thescope or meaning of the claims.

Any advantages and benefits described may not apply to all embodimentsof the invention. When the word “means” is recited in a claim element,Applicant intends for the claim element to fall under 35 USC 112(f).Often a label of one or more words precedes the word “means.” The wordor words preceding the word “means” is a label intended to easereferencing of claims elements and is not intended to convey astructural limitation. Such means-plus-function claims are intended tocover not only the structures described herein for performing thefunction and their structural equivalents, but also equivalentstructures. For example, although a nail and a screw have differentstructures, they are equivalent structures since they both perform thefunction of fastening. Claims that do not use the word “means” are notintended to fall under 35 U.S.C. 112(f).

The foregoing description of the embodiments of the invention has beenpresented for the purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed. Many combinations, modifications and variations are possiblein light of the above teaching. For instance, in certain embodiments,each of the above described components and features may be individuallyor sequentially combined with other components or features and still bewithin the scope of the present invention. Undescribed embodiments whichhave interchanged components are still within the scope of the presentinvention. It is intended that the scope of the invention be limited notby this detailed description, but rather by the claims.

Having described the disclosed subject matter, what is claimed as newand desired to be secured by Letters Patent is:
 1. A system for removingan existing core from a DECD housing comprising: a core press stationhaving a piston and a working platform; a control station forcontrolling movement the piston; and a decore shaft connected to thepiston, whereby movement of the piston is configured to push theexisting core out of the DECD housing.
 2. The system of claim 1, whereinthe system further comprises: a push plate positioned upon the workingplatform, the push plate having a first internal aperture configured topass the existing core therethrough; a pushout donut demountablyconnected to the push plate, the pushout donut having a second internalaperture configured to pass the existing core therethrough; and acollection container connected between the push plate and the pushoutdonut, the collection container configured to receive the existing core.3. The system of claim 1, wherein the decore shaft comprises: a decoreshaft portion having a first female aperture configured to connect tothe piston; and a decore engagement plate disposed opposite the firstfemale aperture.
 4. The system of claim 2, wherein the first internalaperture comprises a first diameter, the first diameter is greater thanan inside diameter of the DECD housing.
 5. The system of claim 2,wherein the second internal aperture comprises a second diameter, thesecond diameter is approximately equal to an inside diameter of the DECDhousing.
 6. The system of claim 1, wherein the control station comprisesa two-handed sensor system for activation control of the core pressstation.
 7. A system for installing a replacement core into a DECDhousing comprising: a core press station having a piston and workingplatform; a control station for controlling movement of the piston; arecore shaft connected to the piston; and a stuffing funnel configuredto couple to the DECD housing proximate an upper end of the DECDhousing, whereby movement of the piston is configured to press thereplacement core through the stuffing funnel and into the DECD housing.8. The system of claim 7, wherein the system comprises a spacerconnected to the working platform, the spacer configured to fit withinthe DECD housing proximate a lower end of the DECD housing.
 9. Thesystem of claim 7, wherein the recore shaft comprises: a recore shaftportion having a second female aperture configured to connect to thepiston; and a recore engagement plate disposed opposite the secondfemale aperture.
 10. The system of claim 7, wherein the systemcomprising an adjustable wrapping station.
 11. The system of claim 10,wherein the adjustable wrapping station comprises a set of rollers forsupporting the replacement core.
 12. The system of claim 7, wherein thesystem comprises a matting configured to the replacement core.
 13. Thesystem of claim 7, wherein the control station comprises a two-handedsensor system for activation control of the core press station.
 14. Aprocess for removing an existing core from a DECD housing, comprisingthe steps of: providing a core press station having a working platform;connecting a collection container between the working platform and theDECD housing; aligning the DECD housing over the collection container;pressing the existing core out of the DECD housing; and collecting theexisting core into the collection container.
 15. The process of claim14, wherein the process further comprises the step of removing anobstruction from the DECD housing prior to the aligning step.
 16. Theprocess of claim 14, wherein the process further comprises the step ofsealing the collection container.
 17. A process for inserting areplacement core into a DECD housing, comprising the steps of: providinga core press station having a working platform; coupling a stuffingfunnel to the DECD housing; wrapping the replacement core with amatting; aligning the replacement core with the DECD housing; andpressing the replacement core through the stuffing funnel and into theDECD housing.
 18. The process of claim 17, wherein the process furthercomprises the steps of: determining an overhang distance between anunobstructed side of the DECD housing and a face of an existing core;and stopping the pressing step when the replacement core is positionedapproximately the overhang distance from the unobstructed side of theDECD housing.
 19. The process of claim 18, wherein the process furthercomprises the steps of: selecting a spacer based the overhang distance;placing the spacer onto the working platform; and aligning the DECDhousing over the spacer.
 20. The process of claim 17, wherein theprocess further comprises the steps of: determining a housing flowdirection of the DECD housing; determining a core flow direction of thereplacement core; and aligning the core flow direction with the housingflow direction.
 21. The process of claim 17, wherein the process furthercomprises the step of selecting the stuffing funnel based on an insidediameter of the DECD housing and an outside diameter of the replacementcore.
 22. The process of claim 17, wherein the process further comprisesthe step of inspecting an interior surface of the DECD housing.
 23. Theprocess of claim 17, wherein the process further comprises the step ofwrapping the matting with a wrapping material.